Collapsible container

ABSTRACT

A container includes a plurality of walls extending upward from a base. At least one support is movable between a retracted position and a support position. The support is pivotably connected to a first wall such that it can extend further into a mouth of the container.

This application claims priority to U.S. Provisional Application No.61/081,353, filed Jul. 16, 2008.

BACKGROUND OF THE INVENTION

The present invention relates generally to collapsible crates and moreparticularly to a collapsible crate with support members for supportinganother container thereon.

Collapsible crates are well known. Four walls each connected via a hingeto a base are selectively movable about the hinge between a useposition, in which the wall is generally perpendicular to the base, anda collapsed position onto the base. Various latch mechanisms have beenprovided to connect adjacent walls at the corner to selectively lock thecrate in the use position.

Some collapsible crates also include retractable supports so thatanother, different-type container (typically a nestable container) canbe supported thereon. One such crate includes end walls each having asupport that is pivotable between a support position and a retractedposition. Lower ends of the supports are pivotably connected to the endwalls, with the upper edges of the supports retractable below the upperedges of the end walls. The supports on the collapsible crates do notextend very far into the mouth of the container (i.e. not far from theend wall). In contrast, the nestable crates include supports that arepivotably connected to the side walls, so the supports easily extendmuch further into the mouth of the crate in the support position. As aresult, one problem with some of these collapsible crates is that thenestable crate can fall in between the supports if the nestable crate isnot correctly placed on the supports.

Some of the existing crates automatically deploy the support when theend wall is pivoted to the upright position. Due to the position of thesupport on the interior surface of the end wall, the user has a tendencyto grab both the support and the end wall when pivoting the end wall tothe upright position. As the end wall reaches the upright position, thesupport must escape the grip of the user in order to be deployed, whichis inefficient and uncomfortable for the user.

Another problem is that supports in some collapsible crates aresometimes knocked back toward the retracted position as the uppercontainer is placed on the supports.

SUMMARY OF THE INVENTION

The present invention provides a container having a plurality of wallsextending upwardly from a base. At least one wall has a supportpivotably mounted by a hinge. The support is pivotable between a supportposition where it can support another container thereon and a retractedposition against the wall.

In one feature of the present invention, the end wall can be movedtoward the collapsed position while the support is in the supportposition, but the support is pivoted into the retracted position just asthe end wall contacts the base. This can provide several other optionalbenefits. First, when the end wall is collapsed onto the base, thesupport is spaced away from the upper edge of the end wall, so the usercan grasp the end wall without also grasping the support. Second, thesupport must be lifted to be retracted, so it is unlikely that placinganother container thereon could knock the support back to the retractedposition. Third, the contact area of the support on the side wall can beincreased, increasing the strength of the support. Fourth, the supportextends further into the mouth of the crate, providing a more stablestacking surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a container according to one embodimentof the present invention with its walls in an assembled, upright, useposition.

FIG. 2 is a perspective view of the container of FIG. 1 with its wallsin a collapsed position.

FIG. 3 is a top view of the container of FIG. 1.

FIG. 4 is a side view of the container of FIG. 1.

FIG. 5 is an end view of the container of FIG. 1.

FIG. 6 is an interior view of one of the corners of the container ofFIG. 1.

FIG. 7 is an enlarged view of the corner of FIG. 6.

FIG. 8A is a top perspective view of one end of the support.

FIG. 8B is a bottom perspective view of the support of FIG. 8A.

FIG. 9 is a perspective view of one end of one of the end walls.

FIG. 10 is an exterior perspective view of the corner of FIG. 6.

FIG. 11 shows the end wall being moved between the upright position andthe collapsed position.

FIG. 12 shows the end wall moving closer to the collapsed position.

FIG. 13 shows the end wall in the collapsed position on the base.

FIG. 14 is a side view, broken away, of the container of FIG. 13.

FIG. 15 shows the container of FIG. 1 with another, different containerstacked on the support.

FIG. 16 is an interior perspective view of the corner of FIG. 6 with thesupport being pivoted toward the retracted position.

FIG. 17 is a view similar to that of FIG. 16 with the support in theretracted position.

FIG. 18 is an enlarged end view of a corner of the container.

FIG. 19 is a section view taken along line 19-19 of FIG. 18 and showingthe support in both the support position and the retracted position.

FIG. 20 is a section view taken along line 20-20 of FIG. 18 and showingthe support in both the support position and the retracted position.

FIG. 21 is a section view taken along line 21-21 of FIG. 18 showing thesupport in the retracted position.

FIG. 22 a view similar to that of FIG. 21 showing the support in thesupport position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 is a perspective view of a collapsible container 10. Thecontainer 10 includes a base 12, upstanding side walls 14 (or longwalls) and upstanding end walls 18 (or short walls). The end walls 18are pivotably connected along short edges of the base 12. The side walls14 are pivotably connected to side upstanding portions 16 formedintegrally with the base 12. Each end wall 18 includes a handle portion19 defined above a handle opening 21.

Each end wall 18 has a support 20 formed of Acetal, polypropylene, glassfilled Nylon or other suitable material. The support 20 is pivotablymounted to an upper end of the end wall 18. The supports 20 are shown inFIG. 1 pivoted to a support position, where they project into theinterior of the container 10 so they can support another containerstacked thereon. The supports 20 each include a tab 22 projecting fromeach end into the adjacent side wall 14. A flange 24 protrudesdownwardly from each tab 22. An upper flange 26 protrudes upwardly fromeach tab 22.

The interiors of the side walls 14 each include a pair of curvedchannels 30 formed therein with spaced-apart, upwardly-directedprojections or tabs 32 spaced inwardly of the channels 30. The channels30 are aligned with the tabs 22 on the supports 20, so that the endwalls 18 can be pivoted onto the base 12 prior to the side walls 14being collapsed, such that the side walls 14 are collapsed onto the endwalls 18, as shown in FIG. 2.

FIG. 3 is a top view of the erected container 10 of FIG. 1. FIG. 4 is aside view of the container 10. FIG. 5 is an end view of the container10.

FIG. 6 is an interior perspective view of a quarter of the container 10(the rest of the container is symmetric, as shown in FIG. 1). As shown,the side wall 14 includes a rail 38 at the top of the curved channel 30and generally aligned with the tabs 32. The interior of the sideupstanding portion 16 includes a channel 34 opening to the bottom of thecurved channel 30 and extending further along the side of the container10. As shown in FIG. 7, the flange 24 of the support 20 is receivedbehind the rail 38 and in the channel 30, such that tab 22 of thesupport 20 interlocks with the side wall 14.

FIG. 8A is a top rear perspective of a one end of the support 20. Thesupport 20 includes an elongated support portion 40 having a front rail42 extending upwardly therefrom. The support portion 40 extends betweenouter ends of two arms 44 (one shown) that pivotably connect at theirinner ends to the end wall 18 (FIG. 7). At the inner end of the arm 44,a hinge portion includes a cylindrical recess 46. A pin 48 protrudesinwardly from the arm 44 adjacent the recess 46.

FIG. 8B is a bottom front perspective of end of the support 20 of FIG.8A. As shown, the flange 24 is elongated along most of the arm 44 anddefines a channel 50 adjacent thereto having an upper surface 51. Thearm 44 has a reinforced area 49 for transferring the load from theelongated support portion 40 to the channel 50.

FIG. 9 illustrates a side end 52 of one of the end walls 18. Near theupper edge, the end wall 18 includes a hinge pin 54 having an arcuaterecess 56 adjacent thereto.

FIG. 10 is an exterior perspective view of one corner of the container10. The pin 48 of the support 20 is slidably received in the arcuaterecess 56 of the end wall 18. The hinge pin 54 of the end wall 18 isrotatably received in the recess 46 of the support 20. Thus, as thesupport 20 pivots on the end wall 18 about the hinge pin 54, the pin 48slides within the arcuate recess 56 of the end wall 18.

FIG. 11 illustrates the end wall 18 as it is being collapsed toward thebase 12, after the latch 36 is released. The flange 24 of the support 20is retained behind the tabs 32 so that the tab 22 is retained in thechannel 30 in the side wall 14. Thus, the support 20 is initially in thesupport position as the end wall 18 is collapsed. As shown in FIG. 12,the support 20 is generally in the support position relative to the endwall 18 as the support 20 passes through the side wall 14 as the endwall 18 is moving toward the collapsed position. The tab 22 and flange24 (not visible in FIG. 12) then pass into the channel 34 on theinterior of the side upstanding portion 16, where they contact a curvedsurface 35 that pivots the support 20 upwardly relative to the end wall18, so that the end wall 18 can lie flat on the base 12 as shown inFIGS. 13 and 14.

When the end wall 18 is subsequently erected again, the process isrepeated in reverse, such that the support 20 is in the support positionagain by the time the end wall 18 is latched to the side wall 14 asshown in FIG. 6. It should be noted that the handle portion 19 of theend wall 18 can be grasped in FIG. 13 and held by the user withoutinterference from the support 20 as the end wall 18 is latched intoposition with the side walls 14. In the container 10 shown in thedrawings, the support 20 always leaves room for the user to grasp thehandle 19.

With the supports 20 in the support position, another container 100 canbe supported on the supports 20, as shown in FIG. 15. With the support20 extending substantially perpendicularly to the end wall 18 from itspivot point, the support 20 is resistant to being accidentally knockedback out of the support position during the placement of the container100 on the supports 20. Further, since the support 20 extends into theinterior of the container 100 substantially farther than prior artsupports, it is easier to place the container 100 stably on to thesupports 20.

During loading of the container 10, the supports 20 can be pivoted to anupright position uncovering the mouth of the container 10. FIG. 16illustrates one of the supports 20 being pivoted upwardly relative tothe end wall 18. FIG. 17 illustrates the support 20 in the retracted,upright position.

FIG. 18 is an enlarged exterior end view of one corner of the container10 for the purpose of demonstrating the section lines for FIGS. 19, 20and 21. FIG. 19 illustrates a section view through the end wall 18 andsupport 20, which is shown in both the support position and in theretracted position. The hinge pin 54 of the end wall 18 is rotatablyreceived in the recess 46 of the support 20. The support 20 pivots aboutan axis P that is above a load plane of the support 20 in the supportposition (i.e. the plane where the support 20 contacts the container 100in FIG. 15, which is the upper surface of the arm 44), which prevents auser from accidentally bumping the support 20 out of the supportposition.

Referring to FIG. 20, the pin 48 moves between a lower position when thesupport 20 is in the support position and an upper position when thesupport 20 is in the retracted, upright position. In the upper position,the pin 48 contacts a stop surface 60 that limits any further movementof the support 20. In the retracted position, the center of mass of thesupport 20 is inward of the pivot axis P, such that the support 20 willbe naturally returned to the support position by force of gravity whenreleased.

Referring to FIG. 21, when the support 20 is in the upright retractedposition (the support 20 in the support position is not shown in FIG.21), the arm 44 abuts a stop surface 64 on the side wall 14 that limitsthe rotation of the support 20. In the retracted position, the weight ofthe support 20 is inward of the pivot axis P, such that the support 20will be naturally returned to the support position by force of gravitywhen released. However, when the end wall 18 is collapsed onto the base12, the support 20 will be able to pivot fully upward relative to theend wall 18 so that the end wall 18 and support 20 can lie flat on thebase 12, as shown in FIGS. 13 and 14, because it will not contact thestop surface 64 on the side wall 14.

Additionally, if the end wall 18 is moved toward the collapsed positionwhen the support 20 is in the retracted position shown in FIG. 21, thecontact of the support 20 with the stop surface 64, which is below thepivot point P of the support 20, will force the support 20 to rotatetoward the support position as shown in FIG. 22.

FIG. 22 is taken along the same section line as FIG. 21, but shown withthe support 20 in the support position. As shown, the upper surface 51of the channel 50 formed on the underside of the arm 44 of the support20 matches the upper edge of the rail 38 on the side wall 14. The amountof surface contact between the support 20 and the side wall 14 in thisarea is maximized, as this is where most of the load is supported. Theflange 24 and rail 38 are elongated to provide maximum material strengthinterlocking between the support 20 and side wall 14.

In accordance with the provisions of the patent statutes andjurisprudence, exemplary configurations described above are consideredto represent a preferred embodiment of the invention. However, it shouldbe noted that the invention can be practiced otherwise than asspecifically illustrated and described without departing from its spiritor scope. For example, in any of the occurrences above, the hingemembers and hinge pins could be reversed and formed on opposite parts.Alphanumeric identifiers on method steps are for convenient reference independent claims and do not signify a required sequence of performanceunless otherwise indicated in the claims.

1. A container comprising: a base; a plurality of walls extending upwardfrom the base, the plurality of walls including a first wall and asecond wall; and a support mounted to the first wall and movablerelative to the first wall between a retracted position and a supportposition, wherein the first wall is pivotable toward a collapsedposition on the base when the support is in the support positionrelative to the first wall.
 2. The container of claim 1 wherein thesecond wall includes an arcuate channel formed on interior surface, anend of the support extending into the channel.
 3. The container of claim2 wherein the end of the support moves in the channel as the first wallis pivoted toward a collapsed position on the base.
 4. The container ofclaim 3 wherein the support extends further into a mouth of thecontainer when the support is in the support position than when thesupport is in the retracted position.
 5. The container of claim 4wherein the support is pivotably mounted to the first wall and pivotablerelative to the first wall between the support position and theretracted position.
 6. The container of claim 5 wherein the support ispivoted to the retracted position when the first wall is collapsed ontothe base.
 7. The container of claim 6 wherein the support in theretracted position contacts a surface of the second wall as the firstwall is pivoted away from the upright position thereby moving thesupport to the support position.
 8. The container of claim 4 wherein thesecond wall includes at least one upward projection adjacent thechannel, the end of the support including a downward projectioninterlocking behind the at least one upward projection as the first wallis moved toward the collapsed position on the base.
 9. The container ofclaim 1 wherein the support is partially supported on the second wall inthe support position.
 10. A container comprising: a base; a plurality ofwalls extending upward from the base, the plurality of walls including afirst wall and a second wall each pivotable between an upright positionand a collapsed position on the base; and a support movable relative tothe first wall between a retracted position and a support position, thesupport extending further into a mouth of the container when the supportis in the support position than when the support is in the retractedposition, wherein the first wall is pivotable to a position between theupright position and the collapsed position while the support is in thesupport position relative to the first wall.
 11. The container of claim10 wherein the support is pivoted by the second wall to the retractedposition as the first wall is collapsed onto the base.
 12. The containerof claim 10 wherein the support is pivotable relative to the first wallabout a pivot axis and wherein an upper support surface of the supportis lower than the pivot axis when the support is in the supportposition.
 13. A method for using a collapsible container having a base,a first wall and a second wall, and a support mounted to the first wall,the method including the steps of: a) moving the support from aretracted position toward an interior of the container to a supportposition; and b) while the support is in the support position, movingthe first wall from an upright position toward a collapsed position onthe base.
 14. The method of claim 13 further including the step ofmoving the support to the retracted position as the first wall is movedinto the collapsed position on the base, wherein the support isgenerally parallel to the first wall when the support is in theretracted position.
 15. The method of claim 13 wherein the support ismoved to the support position by contact with the second wall as thefirst wall is moved from the upright position toward the collapsedposition.